CKFCar Known Faults
SevereAffected: 2004-201170,000–120,000 miles

Ford Focus Mk2 1.6 TDCi 110bhp — Clutch Slave Cylinder / Concentric Bearing Leak

The concentric slave cylinder (CSC) inside the gearbox bellhousing fails, leaking hydraulic fluid and causing clutch failure.

Severity

Severe

DIY Difficulty

Professional Only

Est. Cost

£400–£800

OBD Codes

None

Component Diagram

Clutch

Typical layout and location for the Clutch assembly.

Clutch diagram
Reference Illustration

Symptoms

  • Clutch pedal stays flat to the floor
  • Difficulty engaging gears, especially 1st and Reverse
  • Pool of brake fluid under the gearbox bellhousing

Root Cause

The seals inside the concentric slave cylinder wear out. Because it is mounted inside the bellhousing on the gearbox input shaft, the entire gearbox must be removed to replace a £40 part.

How To Fix

  1. Check brake/clutch fluid reservoir level (it will be low).
  2. Gearbox must be removed to access the CSC.
  3. Always replace the entire clutch kit at the same time, as the leaking fluid ruins the friction plate.
  4. Cost: £400-800

Estimated Repair Costs

Repair OptionEst. Cost (GBP)
DIY (parts only)£160–£320
Independent Garage£400–£800
Main Dealership£640–£1280

Other Faults on This Variant

EGR Valve Failure

Moderate
2005-201160,000–120,000 miles£80–£300

The EGR valve is a common failure on the 1.6 TDCi engine, causing power loss, rough idle, and excessive smoke.

Dual Mass Flywheel (DMF) Failure

Severe
2004-201180,000–150,000 miles£600–£1200

DMF failure is one of the most expensive known faults on the 1.6 TDCi. Typically requires replacement of flywheel and clutch together.

Turbocharger Failure

Severe
2004-2011100,000–180,000 miles£400–£900

Turbo failure on the 1.6 TDCi is common at higher mileages, often caused by oil starvation or sludge blockage.

Disclaimer: Repair cost estimates are indicative and based on community data. Always get a quote from a qualified mechanic before proceeding with any repair.